Reply To: Broken off screws advice

[JOSEPH BRINCAT]

All good advice, each suggestion may prove best for a particular situation and/ or availability of critical resources. In general, if the bolt or stud broke off in a failed attempt unscrew, forget about easy-outs or left hand drills. If you have access to a welder, the “weld a nut” on the stub is about a sure fix. When resorting to the drilling out approach, accurately centering your drilled hole is essential for success. Rigid machine tool set-up ( bridgeport !) is best if you have the tools. When doing free hand or common drill press, the use of a guide bushing is best. A steel plate was suggested, good, or a jury rigged bushing as green-thumbs used. Another good bushing plate, use the mating part ( like a cylinder head) bolted in place using the good bolts, fit a bushing in the subject hole to suit the tap drill size of the broken thread.
Another unusual fix.( not tried) … search use of alum to desolve steel fastener from aluminum part.

Joe B